Method for Manufacturing a Waterproof and Breathable Article of Clothing

ABSTRACT

The invention relates to a method for manufacturing a waterproof and breathable article of clothing  1  comprising an envelope  2  that has inner  3  and outer  4  surfaces, the method involving: at least one step of coating ( 100 ), during which the inner surface  3  is outward-facing, comprising coating the outward-facing inner surface with a solution  6  with a base of at least one polymer, with air A under pressure being injected into the envelope during the coating, then drying the envelope in order to form a first layer  10  of waterproof and breathable polymer on the inner surface; and at least one step of impregnation ( 200 ), during which the inner surface  3  is inward-facing, comprising pouring into the envelope a solution  11  with a base of at least one polymer, removing the excess solution  11,  injecting air A under pressure into the envelope, and drying the envelope in order to form a second layer  15  of waterproof and breathable polymer on the first layer  10.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This application claims priority under 35 USC 119 and/or 365 of FrenchPatent Application No. FR-12 61097 filed on Nov. 21, 2012 with theFrench Institut National de la Propriété Industrielle (INPI). Thecontents of the above-identified Application are relied upon andincorporated herein in their entirety by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a method for manufacturing a waterproof andbreathable article of clothing, as well as such an article obtained byimplementing such a method.

It applies especially to sports articles intended for use in difficultclimatic conditions due to the cold and/or inclement weather, such asfor example gloves, shoes, insulated slippers, bonnets or hoods.

2. Description of the Related Art

During the practice of sports, the body gives off perspiration, inparticular in the form of water vapour. However, wearing unsuitablearticles of clothing, for example conventional waterproof articlesintended to protect against the cold and/or inclement weather, can beuncomfortable, in that these articles do not allow the water vapour tobe removed towards the exterior.

In order to overcome these disadvantages, waterproof and breathablearticles of clothing are known which are arranged to prevent thehumidity coming from the exterior from penetrating inside said articleswhile allowing the water vapour generated by the body of the wearer tobe removed to the outside.

To do so, waterproof and breathable articles are known comprising anouter envelope generally at least water-repellent, an inner lininghaving thermal insulation properties, as well as a waterproof andbreathable insert arranged between said envelope and said lining. Theinsert comprises in particular an impermeable membrane but which allowsthe water vapour to pass in order to confer the expected breathability,for example by being microporous or hydrophilic.

However, these articles do not provide entire satisfaction, in thattheir manufacture is long and expensive. Moreover, when used during highhumidity conditions, the water coming from the exterior can pass throughthe envelope via its seam holes, the impermeability of which isgenerally lacking, then be stopped by the insert, in such a way thatsaid water is retained between said envelope and said insert whilewaiting to be removed by evaporation. However, this water, by beingretained as such in the article of clothing, can over time generate asensation of cold and/or humidity for the wearer, thus rendering thewearing of said article unpleasant for said wearer.

Furthermore, the presence of water in the vicinity of the insertcompromises the removal of the water vapour generated by the body of thewearer, in such a way that said water vapour remains inside the articleof clothing and is condensed, which also constitutes discomfort for thewearer.

In addition, when the wearer is exposed to wind, the water retainedbetween the envelope and the insert evaporates slowly, which alsogenerates a sensation of cold for the wearer. Moreover, the drying timeof the article of clothing is very greatly increased, which renders itsuse less pleasant after a first use in high humidity conditions.

BRIEF SUMMARY OF THE INVENTION

The invention aims to improve prior art by proposing a method formanufacturing an article of clothing wherein a waterproof and breathablebarrier is formed directly on the inner surface of the envelope of saidarticle, which makes it possible to prevent water weight gain of saidarticle when it is used in a wet environment while improving its qualityand its lifespan.

For this purpose, according to a first aspect, the invention relates toa method for manufacturing a waterproof and breathable article ofclothing, said article comprising an envelope that has an inner surfaceintended to be worn in the vicinity of a portion of the body of a wearerand an outer surface opposite said inner surface, said method providingfor:

-   -   at least one step of coating (100), during which said envelope        is turned over in such a way that its inner surface is        outward-facing, said step providing for coating said inner        surface with a solution with a base of at least one waterproof        and breathable polymer, with air under pressure being injected        into said envelope during said coating, then for drying said        envelope in order to form a first layer of waterproof and        breathable polymer on said inner surface; and    -   at least one step of impregnation (200), during which said        envelope is turned over in such a way that its inner surface        covered with the first layer of polymer is inward-facing, said        step providing for pouring into said envelope a solution with a        base of at least one waterproof and breathable polymer, for        removing the excess solution from said envelope, for injecting        air under pressure into said envelope, then for drying said        envelope in order to form a second layer of waterproof and        breathable polymer on the first layer.

According to a second aspect, the invention relates to a waterproof andbreathable article of clothing obtained by implementing such a method.

Other particularities and advantages of the invention shall appear inthe following description, made in reference to the annexed figuresdiagrammatically showing the steps of a method according to anembodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flowchart depicting a method in accordance with theinvention.

FIG. 2 is a more detailed flowchart in accordance with the inventionshown in FIG. 1.

FIG. 3 is a more detailed flowchart in accordance with the inventionshown in FIG. 1.

FIG. 4A and FIG. 4B depict a side view and cutaway view respectively ofan exemplary article of clothing prepared for the coating process of themethod shown in FIG. 1.

FIG. 5A and FIG. 5B depict an exemplary article of clothing being coatedby the method shown in FIG. 1.

FIG. 6A and FIG. 6B depict a side view and cutaway view respectively ofan exemplary article of clothing after the coating process of the methodshown in FIG. 1.

FIG. 7A and FIG. 7B depict a side view and cutaway view respectively ofan exemplary article of clothing turned for the impregnating process ofthe method shown in FIG. 1.

FIG. 8A depicts the addition and removal of the solution for theimpregnating process of the method shown in FIG. 1.

FIG. 8B depicts the injection of air during the impregnating process ofthe method shown in FIG. 1.

FIG. 9A and FIG. 9B depict a side view and cutaway view respectively ofan exemplary article of clothing prepared by the method shown in FIG. 1.

FIG. 10A and FIG. 10B depict a side view and cutaway view respectivelyof an exemplary lined article of clothing prepared by the method shownin FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

In relation with the figures, a method for manufacturing a waterproofand breathable article of clothing 1 is described, said article ofclothing comprising an envelope 2 which has an inner surface 3 intendedto be worn in the vicinity of a portion of the body of a wearer and anouter surface 4 opposite said inner surface. As shown in FIG. 1, themethod comprises providing an article of clothing (50), turning theenvelope over in such a way that the inner surface is facing outwards(60), coating the outward-facing inner surface with polymer (100),turning the envelope over in such a way that the inner surface is facinginwards (150), and impregnating the inner surface with polymer (200).

In the embodiment shown, the article of clothing 1 is a glove of themitten type, with a compartment for the thumb and a shared compartmentfor the other fingers. In other embodiments, the article of clothing 1is for example a glove of another type, a shoe, a slipper, a bonnet or ahood.

The method provides for forming a waterproof and breathable barrier 5directly on the inner surface 3 of the envelope 2, which makes itpossible to simply, inexpensively and in a manner that is easy toautomate manufacture articles of clothing 1 with complex and variedshapes such as those described hereinabove. As such, the method offers awide range of choices as for the aesthetics of the articles of clothing1 to be manufactured.

To do so, the method provides at least one step of coating (100), duringwhich the envelope 2 is turned over in such a way that its inner surface3 is outward-facing (60), said step providing for coating said innersurface with a first solution 6 with a base of at least one waterproofand breathable polymer.

In some embodiments, the step of coating (100) provides for using afirst solution 6 comprising a hydrophilic polymer, in particular with apolyurethane base, as much as polyurethane is recognised for itssatisfactory properties as a barrier to liquid water and fortransferring the water vapour in order to confer the expectedbreathability. In some embodiments, the polymer is used in aqueousphase, which makes it possible to use a first solution 6 devoid ofnon-aqueous solvent.

Moreover, as shown in FIG. 2, FIG. 5A and FIG. 5B, the outward-facinginner surface is coated with first solution 6 while injecting air intothe envelope (110). Air A under pressure is injected into the envelope 2during the coating in order to shape it via inflating, which makes itpossible to coat its inner surface 3 homogeneously and, in the casewhere said envelope is assembled by stitching, to prevent the polymerfrom penetrating inside the envelope 2 through the seams. Furthermore,the pressure of the air A is sufficient to provide for the shaping ofthe envelope 2 so that the coating perfectly hugs the three-dimensionalshape of the envelope 2.

To do so, the envelope 2 is placed, after having been turned over, on abase 7 with a shape that is adapted to that of the opening of saidenvelope, said base being connected to a device 8 for injecting air. Thedevice 8 is arranged to inject air A under pressure into said envelopeby the intermediary of said base.

As shown in FIG. 3, in one embodiment, the step of coating (100)provides for coating the inner surface 3 by immersing the envelope 2 ina bath 9 containing the first solution 6 while injecting air into theenvelope (112). In some embodiments, according to the type of thearticle of clothing 1 and the desired performances for said article interms of impermeability and breathability, the temperature of the bath9, the immersion time of the envelope 2 in said bath and/or theconcentration of polymer in the solution 6 are varied.

In another embodiment, shown in FIG. 3, the step of coating (100)provides for coating the inner surface 3 by spraying the polymersolution 6 onto said inner surface 3 while injecting air into theenvelope (114), with the spraying time then being chosen according tothe type of the article of clothing 1 and the desired performances.

The step of coating (100) then provides for drying the envelope 2 inorder to form a first layer 10 of waterproof and breathable polymer onits outward-facing inner surface 3 (120). In one embodiment, theenvelope 2 is placed in an oven, in order to form the layer 10 bycross-linking of the polymer.

In one embodiment, the step of coating (100) provides for injecting airunder pressure into the envelope 2 while it is being dried, with thepressure of the air being sufficient to guarantee the shaping of saidenvelope, which makes it possible to dry said envelope homogeneously. Assuch, as the layer 10 is dried on the shaped envelope 2, a perfectgeometrical concordance is guaranteed between said layer and saidenvelope in order to render the entire inner surface 3 waterproof andbreathable.

In some embodiments, in order to further improve the homogeneity of thelayer 10, the envelope 2 is subjected, after coating and before drying,to a preliminary light drying, for example by using a fan, in order toremove the bubbles that may have formed on the inner surface 3.

As such, after drying of the envelope 2, the inner surface 3 is fullycovered with a thin waterproof and breathable layer 10, as shown in FIG.6B. Furthermore, the layer 10 is formed by cross-linking of the polymer,which allows said layer to be joined with the envelope 2.

As shown in FIG. 2, according to the desired performances for thearticle of clothing, in some embodiments the method provides forrepeating the steps of coating and drying (130) at least two times,which makes it possible to vary the thickness of the first layer 10 bysuperimposition of several sublayers. In some embodiments, the step ofcoating (100) provides in particular for using first solutions 6 ofdifferent compositions at each iteration. In some embodiments, the stepof drying is omitted or shortened between repetitions to provide anincompletely dry or cured sublayer, permitting better cohesion of thenext application of the first solution.

If the envelope 2 is formed by stitching, and in particular byassembling several parts by stitching, the repetition of the step ofcoating (130) makes it possible to guarantee a good coverage of theholes formed by said seams, and therefore a good impermeability of thefinal article of clothing.

The method then provides at least one step of impregnation (200), duringwhich the envelope 2 is turned over in such a way that the inner surface3 covered with the first layer 10 of polymer is inward-facing (150), asshown in FIG. 7B. This step of impregnation (200) provides for pouringinto the envelope 2 a solution 11 with a base of at least one waterproofand breathable polymer (210).

To do so, as shown in FIG. 8A, in some embodiments the turned envelope2, inner surface 3 arranged facing inwards, is arranged on a base 7 witha shape adapted to that of the opening of said envelope, said base beingconnected to a device 12 for injecting liquid supplied by a tank 13containing the second polymer solution 11.

Like the step of coating (100), in some embodiments, the step ofimpregnation (200) uses, for the same reasons as said step of coating, asecond solution 11 comprising a hydrophilic polymer, in particular witha polyurethane base. In some embodiments, the polymer is used in aqueousphase, which makes it possible to use a second solution 11 devoid ofnon-aqueous solvent. In some embodiments, the composition of the firstsolution 6 is the same as the composition of the second solution 11,which reduces manufacturing costs and complexity. In other embodiments,the composition of the second solution 11 is different from that of thefirst solution 6, allowing the selection of advantageously higher orlower viscosity solutions to ensure impregnation without penetratingthrough the envelope, or for the selection of desired surface propertieson the finished product.

Once the first layer 10 of polymer has been covered by the secondsolution 11, the step of impregnation (200) provides for removing theexcess solution 11 from the envelope 2 (220) and for injecting air Aunder pressure into said envelope (230), in order to force said solutionto penetrate into the seams and into any pores or voids in the firstlayer 10 in order to guarantee a perfect sealing of the seams and theinner surface.

To apply the second solution 11, in some embodiments the base 7 isconnected to a device 14 for pumping arranged to pump the secondsolution 11 into the envelope 2 and to return the excess solution 11into a tank, for example the same tank 13 as that used previously, asshown in FIG. 8A. Then, the base 7 is connected to a device 8 forinjecting air arranged to inject air A under pressure into the envelope2 by the intermediary of said base as shown FIG. 8B.

According to the type of the article of clothing 1 and the desiredperformances for said article in terms of impermeability andbreathability, the temperature of the solution 11, the impregnationtime, and/or the concentration in polymer of the solution 11 can inparticular be varied.

In some embodiments, in order to improve the aesthetics of the articleof clothing 1, the envelope 2 is subjected, after the injection of air Aunder pressure, to a suitable rinsing in order to remove the excesssolution 11 of polymer that may have bled onto the outer surface 4 ofsaid envelope during said injection of air.

The step of impregnation (200) then provides for drying the envelope 2in order to form a second layer 15 of waterproof and breathable polymeron the first layer 10 (240). In some embodiments, the envelope 2 isplaced in an oven, in order to form the second layer 15 by cross-linkingof the polymer.

In some embodiments, the step of impregnation (200) also provides forinjecting air under pressure into the envelope 2 while it is beingdried, with the pressure of the air being sufficient to guarantee theshaping of said envelope, which makes it possible to dry said envelopehomogeneously, including in the seams.

As such, after the drying of the envelope 2, the first layer 10 iscovered with a second layer 15 of polymer that is thin, waterproof andbreathable, as shown in FIG. 9B. Advantageously, the polymer of thesecond layer 15 is chosen for its chemical affinity with the polymer ofthe first layer 10 or, if said first layer comprises a superimpositionof sublayers made of different polymers, with the polymer of the last ofsaid sublayers, which allows said second layer to be joined with saidfirst layer, in order to form a waterproof and breathable barrier 5. Forexample, in some embodiments, the first solution 6 and second solution11 used by the steps of coating (100) and of impregnation (200) areidentical, which makes it possible to benefit from a maximum chemicalaffinity.

In particular, if the envelope 2 is formed by stitching, and inparticular by assembling several parts by stitching, the step ofimpregnation (200) makes it possible to seal the last seam holes or anypores or voids that were not covered after the step of coating (100),and as such to provide for optimum and reliable impermeability.

According to the desired performances for the article of clothing 1, insome embodiments, the method provides for repeating the step ofimpregnation (200) at least two times (250), which makes it possible tovary the thickness of the second layer 15 by superimposition of severalsublayers. In some embodiments, the step of impregnation (200) alsoprovides for using solutions 11 of different compositions at eachiteration, for example to select desired surface properties for theoutermost sublayer while maintaining adequate cohesion of the innersublayers to each other and to first layer 10.

The combination of the two steps of coating (100) and of impregnation(200) makes it possible to confer to the article of clothing 1 a perfectglobal impermeability, in particular on the seams, while making itpossible to retain good grasping, good sensations in terms of touch, andgood breathability.

In some embodiments, a lining 16 is arranged in the envelope 2 in orderto cover the inner surface 3 (225) as shown in FIG. 10B. In particular,in some embodiments the step of impregnation (200) provides forarranging the lining in the envelope 2 before it is dried, in order tofix said lining 16 to said envelope during said drying by theintermediary of the second layer 15 of polymer. In particular, if thestep of impregnation (200) is repeated several times, the lining isarranged in the envelope 2 during the last iteration.

In some embodiments, in particular for sports articles intended to beused during difficult climatic conditions, the lining 16 includes atleast one layer of material that has thermal insulation properties, forexample with a base of cotton, foam or polar fleece.

In some embodiments, air under pressure is injected into the lining 16before the second layer of polymer is fully dried or cured, in order toallow said lining 16 to be in close contact with the inner surface 3 ofthe envelope 2. To do so, the lining is arranged in the envelope 2 afterit is impregnated (225), then the lining—envelope 2 unit is arranged onthe base 7 connected to the device 8 for injecting air and air pressureis injected (227), with the whole then being placed in an oven fordrying (245).

As such, during the drying, the second layer 15 is formed bycross-linking of the polymer and makes it possible, thanks to saidcross-linking, to reliably fix the lining to the envelope 2.

We claim:
 1. A method for manufacturing a waterproof and breathablearticle of clothing comprising the steps of: providing an article ofclothing (1), said article comprising an envelope (2) that has an innersurface (3) intended to be worn in the vicinity of a portion of the bodyof a wearer and an outer surface (4) opposite said inner surface;turning the envelope over in such a way that its inner surface (3) isoutward-facing; coating (100) the article, wherein the step of coatingthe article comprises the steps of: coating said inner surface with afirst solution (6) comprising at least one waterproof and breathablepolymer, with air (A) under pressure being injected into said envelopeduring said coating; and drying said envelope in order to form a firstlayer (10) of waterproof and breathable polymer on said inner surface;turning the envelope over in such a way that its inner surface (3)covered with the first layer (10) of polymer is inward-facing; andimpregnating (200) the article, wherein the step of impregnating thearticle comprises the steps of: pouring into said envelope a secondsolution (11) comprising at least one waterproof and breathable polymer;removing the excess second solution (11) from said envelope; injectingair (A) under pressure into said envelope; and drying said envelope inorder to form a second layer (15) of waterproof and breathable polymeron the first layer (10).
 2. The method according to claim 1, wherein thefirst solution (6) and/or the second solution (11) comprises ahydrophilic polymer with a polyurethane base.
 3. A method according toclaim 1, wherein the step of coating the article (100) and/or the stepof impregnating the article (200) is repeated at least two times.
 4. Amethod according to claim 3, wherein the step of coating said innersurface with a first solution (6) utilizes first solutions (6) ofdifferent compositions at each repetition, and/or the step of pouringinto said envelope (11) utilizes second solutions (11) of differentcompositions at each repetition.
 5. A method according to claim 1,wherein the step of coating the inner surface (3) further comprises thestep of immersing the envelope (2) in a bath (9) containing the solution(6) of polymer.
 6. A method according to claim 1, wherein the step ofcoating the inner surface (3) further comprises the step of spraying thesolution (6) of polymer on said inner surface.
 7. A method according toclaim 1, wherein the step of drying the envelope to form a first layer(10) and/or the step of drying the envelope to form a second layer (15)further comprises injecting air under pressure into the envelope (2)while it is being dried.
 8. A method according to any of claims 1,further comprising the step of arranging a lining in the envelope (2)after the excess second solution (11) is removed and before drying saidenvelope, in order to fix said lining to said envelope during saiddrying by the intermediary of the second layer (15) of polymer.
 9. Amethod according to claim 8, further comprising the step of injectingair under pressure into the lining.
 10. A method according to claim 8wherein the lining comprises at least one layer of material that hasthermal insulation properties.
 11. A waterproof and breathable articleof clothing obtained by implementing the method of claim
 1. 12. A methodfor manufacturing a waterproof and breathable article of clothingcomprising the steps of: providing an article of clothing comprising anenvelope having an inner surface and an outer surface; coating saidinner surface with a first solution while pressure is applied to saidouter surface; and impregnating said inner surface with a secondsolution while pressure is applied to said inner surface.
 13. The methodof claim 12, wherein the step of coating said inner surface with a firstsolution further comprises the steps of: turning the article of clothingsuch that said inner surface is outward-facing; and applying said firstsolution to said inner surface while applying air pressure to said outersurface.
 14. The method of claim 12, wherein the step of impregnatingsaid inner surface with a second solution further comprises the stepsof; turning the article of clothing such that said inner surface isinward-facing; applying said second solution to said inner surface; andapplying air pressure to said inner surface after said second solutionis applied.
 15. The method of claim 13 wherein the step of applying saidfirst solution further comprises the step of immersing said article ofclothing at least partially into said first solution.
 16. The method ofclaim 13 wherein the step of applying said first solution furthercomprises the step of spraying said first solution onto at least aportion of said article of clothing.
 17. The method of claim 14 furthercomprising the steps of arranging a liner to the inner surface aftersaid second solution is applied and pressing said liner against saidinner surface.
 18. A method for manufacturing a waterproof andbreathable article of clothing comprising the steps of: providing anarticle of clothing comprising an envelope having an inner surface andan outer surface; turning the article of clothing such that said innersurface is outward-facing; coating said inner surface with a firstsolution comprising at least one waterproof and breathable polymer whileapplying air under pressure to the outer surface to form a layer on saidinner surface; turning the article of clothing such that said innersurface is inward-facing; and impregnating said inner surface with asecond solution.
 19. The method of claim 18, wherein the step ofimpregnating said inner surface with a second solution further comprisesthe steps of: applying said second solution to said layer on said innersurface, wherein said second solution comprises at least one waterproofand breathable polymer; and applying air pressure to said inner surfaceto force said second solution into any pores and voids in said layer;and
 20. The method of claim 18, further comprising the steps of:arranging a liner to the inner surface after impregnating said innersurface with said second solution; and pressing said liner against thesecond solution before the second solution is fully dried or cured tofix the liner to the inner surface.